engine MERCEDES-BENZ ML320 1997 Complete Repair Manual

CHECK ALL VISIBLE PARTS FOR SIGNS OF LEAKS AND DAMAGE - AP00.20-P-0053GH
MODEL 163.113 /128 /136 /154 /157 /172 /174 /175
INSPECTING CHASSIS AND LOAD-BEARING BODY PARTS FOR DAMAGE AND CORROSION - AP00.20-P-0090GH
MODEL 163
with Code Z04/Z07
Model 230AP00.20-P-0001L
Model 414AP00.20-L-0001A
Taxi serviceModels 202, 210AP00.20-P-0007A
Model 203AP00.20-P-0007C
Remove
Detach lower engine
compartment panelingModels 163.172/174/175AR61.20-P-1105GH
Remove noise
encapsulationModel 163.113/128AR94.30-P-5400GH
Check

2If traces of fluid are noted
(e.g. oil), then determine
and correct the cause (on a
separate work order).
Check for leaksEngine:
Transmission
Transfer case
Front axle
Rear axle
Pressure oil pump
3Check for leaks and fixingShock absorbers,
suspension struts
4Inspect for leaks and
conditionRubber boots of front axle
shafts
5Inspect lines and hoses for
leaks and condition, pay
attention to chafing points
and routingRadiator
Fuel system
Exhaust system
Clutch actuation
Automatic transmission
Power steering
Brake system
Install
Install lower engine
compartment paneling.Models 163.172/174/175AR61.20-P-1105GH
Install noise encapsulationModel 163.113/128AR94.30-P-5400GH
1Visual inspectionControl arm mountings and
control arms of front axle

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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RENDER NEW VEHICLES, WHICH WERE IMMOBILIZED OPERATIONAL - AP00.70-P-1001ZZ
MODEL 129, 140, 163, 168, 170, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240
MODEL 461.302 /332 /342 /345
MODEL
463.200 /204 /206 /207 /208 /209 /220 /221 /224/225 /227 /228 /230 /231 /232 /233 /240 /241 /243 /244 /245 /2
4
servicerecommend that the
vehicle fuel tank is
completely filled. Then
allow gasoline engines to
run warm for 2-3 minutes.
Notes on paintwork,
decorative and detachable
components AH98.00-P-9019-01Z
if necessary, corrosion
protection after painting
(Section D) AP98.00-P-0641A
1Perform delivery
inspection
2Check battery AR54.10-P-1129-01A
3
+Vent stationary heater and
top up coolantModel 163, 168, 170, 202,
203, 208, 209, 210, 211,
215, 220, 230, 240, 461,
463
Models 129, 140 with
stationary heater, code 228ra83001291165x
4Check fluid level of
engine cooling system,
correct if necessary and
check corrosion protection
as well as antifreeze and
correct if necessaryModel 129, 140, 163, 168,
170, 202, 203, 208, 209,
210, 211, 215, 220, 230,
240
Model 463 with engine
112, 113AP20.00-P-2010GA
Models 461, 463 with
engines 102, 103, 104,
117, 602, 603, 606, 612,
628AP20.00-P-2010G
Risk of accident caused
by vehicle starting off by
itself when engine is
running. Risk of injury
caused by contusions and
burns during starting Secure vehicle to prevent
it from moving. Wear
closed and snug-fitting
work clothes. Do not grasp
hot or rotating parts.AS00.00-Z-0005-01A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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procedure or when
working near engine
5Start engine Allow to run at idle
speed until oil pressure is
displayed.
6Check refrigerant level of
air conditioning systemModel 129 up to 31.5.96
with automatic air
conditioning, code 581a,AP83.30-P-8312DA
Model 140 up to 31.5.95
with automatic air
conditioning, code 581a
with rear air conditioner,
code 582,
Model 202 up to 30.9.95
with automatic air
conditioning, code 581a,
Models 129, 170, 202,
208, 210, 220 with air
conditioning (or
Tempmatic for USA),
code 580
Models 461, 463 with air
conditioning, code H02AP83.30-P-8312G
7Move the pull switch of
the hydropneumatic
suspension into position N
and allow the engine to
run at increased idle speed
until the vehicle has
reached its normal levelOnly for Hydropneumatic
suspension with automatic
level lowering device and
controlled damping, code
215c, All-round
hydropneumatic
suspension, code 487
8Brake testing on test standModel 129, 140, 170, 202,
203, 208, 209, 210, 215,
220AP42.00-P-4290BA
Models 461, 463AP42.00-P-4290G
9Check brake disks for
signs of corrosion. For vehicles which
were parked for more than
6 months.
10Replace brake fluid For vehicles which
were parked for more than
6 months.
Model 140 as of 1.7.93
except code 471AP42.00-P-4280BA
Model 170 except code
471
Model 202 up to 31.5.94
except code 471

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:52 PMPage 407 © 2006 Mitchell Repair Information Company, LLC.

Repair materials
RETROFITTING & CONVERSION
TABLE OF CONTENTS FOR RETROFITTING AND CONVERTING SPECIAL EQUIPMENT - AN00.10-P-1000NZ
MODEL 163
cleaning agents.
Only for Activated
charcoal filter, code 306:
Cover inside of air inlet
grille on engine hood.
Cleaner
14Treat paintwork using
polishing paste and buffer If films still on
paintwork.
Polish*BR00.45-Z-1015-04A
15Perform treatment using
polish and gloss
preservation.Polish*BR00.45-Z-1013-04A
Gloss preserver*BR00.45-Z-1014-04A
NumberDesignationOrder number
BR00.45-Z-1017-04ACleanerA 001 986 13 71
BR00.45-Z-1014-04AGloss preserverA 000 986 44 74
BR00.45-Z-1015-04APolishA 000 986 43 74
BR00.45-Z-1013-04APolishA 000 986 45 74
AN31.10-P-8080AA Retrofit trailer
couplingModel 163.113 /136 /154 /172 #A as
of 145273,
Model 163.113 /136 /154 /172 #X as
of 708319,
Model 163.128 /175 except styling
package, code U49AN31.10-P-8080AA
AN31.10-P-8080AB Retrofit trailer
couplingModel 163.113 /136 /154 /172 #A as
of 145273,
Model 163.113/136 /154 /172 #X as
of 708319,
Model 163.128 /175 with styling
package, code U49
Model 163.174AN31.10-P-8080AB
AN31.10-P-8080AC Retrofit trailer
couplingModel 163.136 /154 /172 #A up to
145272,
Model 163.136 /154 /172 #X up to
708318AN31.10-P-8080AC
AN91.12-P-0001A Retrofit third seat rowModel
163.113 /128 /136/154 /157 /172 /175AN91.12-P-0001A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:52 PMPage 409 © 2006 Mitchell Repair Information Company, LLC.

TABLE OF CONTENTS FOR SUBSEQUENT INSTALLATION AND CONVERSION OF ACCESSORIES - AZ00.10-P-1000JZ
MODELS 163
AN91.12-P-0002A Retrofit third seat row
automatic easy entry
adjustment facilityModel 163.154/172#A as of 145273
Model 163.136 /154 /172 #X from
708319,
Model 163.113 /128 /157 /175 with
3rd seat row, code 847AN91.12-P-0002A
AN20.30-P-0001RRetrofit coolant
preheaterModel 163.136 with engine 111.977AN20.30-P-0001R
AN20.30-P-0001S Retrofit coolant
preheaterModel 163.154 with engine 112.942AN20.30-P-0001S
AN20.30-P-0001T Retrofit coolant
preheaterModel 163.172 with engine 113.942
Model 163.175 with engine 113.965AN20.30-P-0001T
AN49.10-P-0001ARetrofit system for
diesel particle
reductionEngine 612.963 in model 163 except
particulate filter, code 474AN49.10-P-0001A
AN82.61-P-0001H Retrofit navigation
system Audio 30 APSModel 163 up to 30.6.99 except 6-
disk CD changer, code 819
Model 163 as of 1.7.99 in
combination with CD changer with
D2B fiber optic cable systemAN82.61-P-0001H
AN88.30-P-0001A Retrofitting fender
flapModel 163.113/136 /154 /172 #A up
to 289564 up to 31.8.01
Model 163.113/136 /154 /172 #X up
to 754619 up to 31.8.01AN88.30-P-0001A
AN88.30-P-0003A Retrofitting underride
protectionModel
163.113/128/136/154/157/172/175
except styling package, code U49,
except Parktronic system (PTS), code
220AN88.30-P-0003A
AZ49.10-P-0002B Retrofitting AMG
end pipeEngine 111.977 in model 163.136 except
modification kit, code
U47 except styling package, U49
Engine 112.942 in model 163.154 except
modification kit, code U47
except styling package, U49
Engine 112.970 in model 163.157 except
modification kit, code U47
except styling package, U49
Engine 113.942 in model 163.172 except
modification kit, code U47
except styling package, U49
Engine 113.965 in model 163.175 except AZ49.10-P-0002B

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:52 PMPage 410 © 2006 Mitchell Repair Information Company, LLC.

modification kit, code U47
except styling package, U49
Engine 612.963 in model 163.113 except
modification kit, code U47
except styling package, U49
Engine 628.963 in model 163.128 except
modification kit, code U47
except styling package, U49
AZ82.20-P-0001B Retrofit illuminated
door sill moldingModel 163.113/128/136/154/172/174/175AZ82.20-P-0001B
AZ82.64-P-
0001MA
Retrofitting CD
changerModel 163 as of 1.7.99 along with Audio
10 radio, Audio 30 or COMAND operating
and display unit and D2B fiber optic cableAZ82.64-P-
0001MA
AZ82.70-P-0002A Retrofitting
permanently
installed D-network
telephoneModel 163 up to 30.11.99 Permanently
installed Nokia 6081 telephoneAZ82.70-P-0002A
AZ82.70-P-0002C Retrofitting
permanently
installed D-network
telephoneModel 163 as of 1.12.99 up to 31.8.00
Telephone fixed installation Nokia 6090AZ82.70-P-0002C
AZ82.70-P-
0002GH
Retrofitting
permanently
installed D-network
telephoneModel 163 from 1.9.00 to 30.9.01 except
code 352a, COMAND operating and
display unit, fixed-installation Nokia 6090
telephoneAZ82.70-P-
0002GH
AZ82.70-P-0001A Retrofit D-network
cell phoneModel 163 up to 30.11.99 permanently
installed Nokia 3110 cell phoneAZ82.70-P-0001A
AZ82.70-P-0001D Retrofit D-network
cell phoneModel 163 as of 1.12.99 up to 31.8.00
Portable CTEL Nokia 3110AZ82.70-P-0001D
AZ82.70-P-
0001GH
Retrofit D-network
cell phoneModel 163 as of 1.10.01, only for D-
network portable CTELAZ82.70-P-
0001GH
AZ88.30-P-0002A Retrofitting outer
spare wheel holderModels 163.113/128/136/154/172/175,
except styling package, code U49AZ88.30-P-0002A
AZ82.60-P-0004A Retrofit vehicle
video systemModels 163.136 /154 /172 1A as of
145273, 163.136/154/172 1X as of 708319,
163.113/128/157/174/175 1# left-hand
drive vehicleAZ82.60-P-0004A
AZ82.60-P-0004BRetrofit vehicle
video systemModels 163.136 /154 /172 2A as of
145273, 163.136 /154 /172 2X as of
708319, 163.113/128 /157 /174 /175 2#
right-hand drive vehicleAZ82.60-P-0004B
AZ88.30-P-
0006GH
Retrofit side step barModels 163.113 /128 /136 /154 /172 /175,
except styling package, code U49AZ88.30-P-
0006GH
AZ88.30-P-
0005GHRetrofit protective
side moldingModels 163.113/128/136/154/172/175,
except styling package, code U49AZ88.30-P-
0005GH

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:52 PMPage 411 © 2006 Mitchell Repair Information Company, LLC.

CAPACITIES & SPECIFICATIONS
SPECIFIED ENGINE OILS (SERVICE) - OVERVIEW - BB00.40-P-0223-02A
For Mercedes-Benz and Smart
AZ88.30-P-
0008GH
Retrofit styling
spoilerModels 163.113 /154 #A as of 289565,
163.113 #X as of 754620,
163.128 /157 /175 except styling package,
code U49AZ88.30-P-
0008GH
AZ82.70-P-
0006GH
Retrofit portable
CTELModel 163 as of 1.9.00 up to 30.9.01
portable cellular telephone Nokia 51 xx
and 61xxAZ82.70-P-
0006GH
AZ83.70-P-0009HRetrofitting Telestart
receiverModel 163.###1# up to 31.12.99
Telestart T60 with retrofitted stationary
heaterAZ83.70-P-0009H
AZ83.70-P-
0009HARetrofitting Telestart
receiverModel 163.### 1 # Telestart T70 with
windshield antenna, with retrofitted
stationary heaterAZ83.70-P-
0009HA
AZ83.70-P-
0009HBRetrofitting Telestart
receiverModels
163.113 /128 /136 /154 /157 /172 /174 /175
1# as of 1.9.01 with model year 2002, code
802 Telestart T70 with windshield antenna,
with retrofitted stationary heaterAZ83.70-P-
0009HB
AZ88.30-P-
0004GH
Retrofit step
platformModels 163.136 /154 /172 #A as of
145273,
163.136 /154 /172 #X as of 708319,
163.113/128/157/174/175
with illuminationAZ88.30-P-
0004GH
AZ88.30-P-
0004GI
Retrofit step
platformModels
163.113 /128 /136 /154 /157 /172 /174 /175
without illuminationAZ88.30-P-
0004GI
AZ54.65-P-0001I Retrofit ultrasonic
back-up aidModel 163.1 up to 31.08.01 except spare
wheel holder/spare wheel, code 849,
except trailer hitch, code 550AZ54.65-P-0001I
AZ82.10-P-
0001GHRetrofitting
additional headlampModel 163.113/154 #A as of 289565,
163.113 #X as of 754620,
163.128 /157 /175 except styling package,
code U49, except USA version, code 494a.
with styling spoiler onlyAZ82.10-P-
0001GH
BB00.40-P-0223-02A
Specified engine oils
(service) - overviewFor Mercedes-Benz and
Smart
Sheet 223.2
viscosity classesSheet 224.1 (passenger-car
engines)BB00.40-P-0224-01A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Saturday, October 02, 2010 3:47:52 PMPage 413 © 2006 Mitchell Repair Information Company, LLC.

The temperature ranges in the viscosity classes must be observed for the use of the engine oils (see Sheets 224.1
and 224.2)!
Passenger vehicle engines,
Commercial vehicle engines from the passenger car division,
Single-grade oils are listed on sheets: 228.0, 228.2 - only to be used in summer.
Multigrade oils are listed on sheets 226.9, 228.1/.3/.5/.51, 229.1/.3/.31/.5/.51 - use possible all year round.
Industrial engines from the car sector (series 100, series 600)
Sheet 224.2 (commercial-
vehicle engines)BB00.40-P-0224-02A
Single-grade oilsSheet 228.0BB00.40-P-0228-00A
Sheet 228.2BB00.40-P-0228-02A
Multigrade oilsSheet 226.9BB00.40-P-0226-09A
Sheet 228.1BB00.40-P-0228-01A
Sheet 228.3BB00.40-P-0228-03A
Sheet 228.5BB00.40-P-0228-05A
Sheet 228.51BB00.40-P-0228-51A
Sheet 229.1BB00.40-P-0229-01A
Sheet 229.3BB00.40-P-0229-03A
Sheet 229.31BB00.40-P-0229-31A
Sheet 229.5BB00.40-P-0229-05A
Sheet 229.51BB00.40-P-0229-51A
MB
Specifications
for
Operating
Fluids Sheet
1226.9
Multi-
grade228.0/.1
Single/
multi-
grade226.9229.3
Single/
multi-
grade229.5
Multi-
grade229.5
Multi-
grade229.5
Multi-
grade229.3
Multi-
grade229.3229
Multi-
grade229.5
Multi-
grade229.5
Multi-
grade
Gasoline
engines
M 155 (SLR)------ -•-
AMG engines
except M 155
(SLR)--------•4 .)-
M 111, 137,
272, 273-----••-•-
M 112, 113,
134, 135-----•••••
M 122, 275------•-•-

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Saturday, October 02, 2010 3:47:52 PMPage 414 © 2006 Mitchell Repair Information Company, LLC.

M 160, 160/1,
M 285
(Maybach)--------•-
M 166-----••---
M 266 Turbo,
M 271------••••
Other
M 1xx, M 2xx
that are not
listed above-----••-•-
Diesel engines
without
particulate
filter (DPF)
OM660---•----•-
OM 640, 642,
646 in model
series 639
OM 646, 647,
648---/•••-••••
OM611, 612,
613, 628, 639,
668, 664, 665--/•-/••••••••
Other
OM 6xx not
listed above--/•-/••••••••
with
particulate
filter (DPF)
OM 629, 639,
640, 646, 647,
648, 664, 665
OM 639 in
model series
639 and 906----•--•-•
OM
660
(EU3/EU4 not
with regulated
DPF)---•----•-
Other
OM 6xx with
DPF not listed
above----•--•-•

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:52 PMPage 415 © 2006 Mitchell Repair Information Company, LLC.

Commercial vehicle engines, Industrial engines from the commercial vehicle sector (BR 300, BR 400, BR
500, BR 900)
This table only serves as an overview!
The detailed maintenance and oil change regulations can be found in the maintenance booklet for the respective
vehicle/ major assembly.
• Enable
o Can only be used in exceptional cases or under certain operating conditions/in certain applications.
- Must not be used
1. Sheets 227.0/. 1 no longer exist! Replaced by engine oils in sheets 228.0/. 1/.2/.3/.5/51.
2. Use in combination with low-sulfur (S <50 ppm) or sulfur-free (S <10 ppm) fuel! If fuels with sulfur
contents of S> 500 ppm are being used, the oil change intervals must be reduced!
3.Restriction: Onl
y "Mobil 1 5W-50", SAE 5W-50, sheet 229.3 is approved!
MB
Specifications
for
Operating
Fluids Sheet
1.)226.9
Multi-
grade228.0/.1
Single/
Multi-
grade226.9229.3
Single/
Multi-
grade229.5
Multi-
grade228.51 '
Multi-
grade229.1
Multi-
grade229.3
Multi-
grade229.31
Multi-
grade229.5
Multi-
grade229.51
Multi-
grade
Commercial
vehicles,
buses without
particulate
filter
BR 300, 400,
500, 900; OM
457, 460 up to
and including
Euro 3-o/•o/•••-----
BR 500, 900;
OM 457, 460
Euro 4/5--o/•••-----
Gas engines•---•-----
Commercial
vehicles,
buses with
particulate
filter
BR 500, 900;
OM 457, 460--oo•-----

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:52 PMPage 416 © 2006 Mitchell Repair Information Company, LLC.